Roof mounting system

ABSTRACT

A roof mounting system and method for mounting an array of discrete modules such as a plurality of photovoltaic panels to a roof comprising a plurality of support rails configured to cooperative support the plurality of photovoltaic modules securely adhered to the roof with a spray polyurethane foam covered by a protective coating of elastomeric material.

CROSS-REFERENCE

This application claims priority from pending provisional patent application Ser. No. 61/687,711 filed Apr. 30, 2012.

BACKGROUND

1. Field of the Invention

A roof mounting system and method for mounting an array of discrete modules to a roof.

2. Description of the Prior Art

Existing attachment systems for mounting solar and other equipment to the exteriors of building envelopes commonly follow one of two general approaches.

The first attachment system includes penetration of the envelope by mechanical attachment devices.

The second system consists of ballasting equipment in place by loads of magnitudes greater than the predicted wind uplift and overturning forces.

Each approach has significant drawbacks. For example, mechanical anchors compromise the integrity of the building envelope and increase the likelihood of leaks and magnify wind forces by concentrating them all at a limited number of attachment points.

On the other hand, ballasting can require loads greater than the building envelope or roof can support. Most commercial roofs are designed for a live load of 40 pounds per square foot, whereas wind uplift in Florida and other high wind areas can exceed 80 per square foot.

While some of the prior art may contain some similarities relating to the present invention, none of them teach, suggest or include all of the advantages and unique features of the invention disclosed hereafter.

The present invention overcomes these problems by keeping the wind as a distributed force over the entire footprint on the building envelope of the equipment being installed or a lesser attachment area as needed based upon site specific wind engineering.

SUMMARY OF THE INVENTION

The present invention relates to a roof mounting system and method for mounting an array of discrete modules to a roof.

The roof mounting system employs structural roofing insulation or water proofing adhesive such as spray polyurethane foam or other chemical agent to secure the roof mounting system in place. This transfers the load forces directly to large areas of the surface covering of the building envelope. Securing the roof mounting system in this manner does not alter the wind forces at a given location other than decoupling the internal portion (18%) of the total wind force from the external portion of the total wind force (82%). The building envelope resists internal pressure.

Furthermore, the roof mounting system resists the external wind force and transfers the force through the adhesion to the envelope of the building structural framing. The only change in forces experienced by the building framing is the relatively small additional gravity load of the roof mounting system adhered to the envelope.

The roof mounting system is particularly useful in securing a solar panel array to a roof by spray polyurethane foam that creates a minimal gravity load of about 6 pounds per square foot for typical installation well within the acceptable live load on any current code compliant building.

The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and object of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which: Similar reference characters refer to similar parts throughout the several views of the drawings.

FIG. 1 is a perspective view of the roof mounting system of the present invention.

FIG. 2 is a view of a stanchion of the present invention.

FIG. 3 is a detailed disassembled view of the stanchion of the present invention.

FIG. 4 is a partial view of an array of photovoltaic modules mounted to a roof on support rails secured to the roof by a plurality of stanchions.

DETAILED DESCRIPTION OF THE INVENTION

As shown in FIGS. 1 and 4, the present invention relates to a roof mounting system and method for mounting an array of discrete modules to a roof.

Specifically, a plurality of support rails each indicated as 1 is arranged on a roof 3 to cooperatively form a grid to support a plurality of discrete modules such as a photovoltaic panels 5.

The plurality of support rails 1 may be secured or adhered directly to the roof 3 by a spray polyurethane foam 2 upon the spray polyurethane 2 may be combined with or covered by a protective coating of elastomeric material.

Alternately, the support rails 1 may be mounted on a plurality of stanchions each generally indicated as 6. Each stanchion 6 comprises a base plate 7 coupled to an upright member 8 by a coupling element 9. Each stanchion 6 further includes a fastening member 10 including a centrally disposed aperture or hole 11 to receive a fastener 12 thereto to secure the rails 1 to a corresponding upright member 8 of the corresponding stanchion 6 by a corresponding rail clamp 13.

The base plate 7 of each stanchion 6 is embedded or adhered to the roof 3 by the spray polyurethane foam 2.

Spray polyurethane foam roofing systems exhibit excellent adhesion properties to a variety of substrates including metal, wood, concrete and built up roofing. However, the spray polyurethane foam must be protected by elastomeric coatings or other coverings to prevent UV-induced surface degradation.

Benefits of using spray polyurethane foam as an adhesive include; rigid, lightweight, flexible, wind resistant, effective in extreme weather and temperature conditions and high insulating values.

It will thus be seen that the objects set forth above, among those made apparent from the preceding description are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.

Now that the invention has been described, 

1-6. (canceled)
 7. The method of claim 10 wherein each said base plate is adhered to the roof by embedding said base plate in said spray polyurethane foam. 8-9. (canceled)
 10. A method for mounting an array of discrete modules such as a plurality of photovoltaic panels to a roof comprising a plurality of support rails supporters including a substantially vertical member in fixed spaced relationship to the roof by a plurality of stanchions to cooperative support the plurality of photovoltaic modules secured to the roof by a plurality of stanchions adhered to the roof with a spray polyurethane foam, each said stanchion comprises an upright member including a lower end portion coupled to a base plate to secure said stanchion to the roof and an upper end portion coupled to a fastening member including a centrally disposed aperture or hole to receive a fastener thereto to secure said support rails to a corresponding upright member of a corresponding stanchion by a corresponding rail clamp.
 11. The method of claim 10 wherein said rail clamp comprises a substantially L-shaped member including a first leg disposed substantially parallel to said substantially vertical member and a second leg disposed substantially perpendicular to said first leg and substantially parallel to said base plate.
 12. The method of claim 11 wherein said lower end portion of said upright member is adjustable relative to said base plate to selectively adjust the distance between said support rails and the roof.
 13. The method of claim 12 wherein said fastening member is adjustable relative to said upper end portion of said upright member to selectively adjust the distance between said support rails and the roof.
 14. The method of claim 11 wherein said fastening member is adjustable relative to said upper end portion of said upright member to selectively adjust the distance between said support rails and the roof.
 15. The method of claim 10 wherein said lower end portion of said upright member is adjustable relative to said base plate to selectively adjust the distance between said support rails and the roof.
 16. The method of claim 15 wherein said fastening member is adjustable relative to said upper end portion of said upright member to selectively adjust the distance between said support rails and the roof.
 17. The method of claim 10 wherein said fastening member is adjustable relative to said upper end portion of said upright member to selectively adjust the distance between said support rails and the roof. 